Komatsu Hydraulic Excavator Pc300 8 60001 Shop Manual

Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.

Note 1:Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)

Note 2:This shop manual can be supplied for each Form No.

Note 3:To file this shop manual in the special binder for management, handle it as follows:

•Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below:

•File overview and other materials in sections in the order shown below and utilize them accordingly.

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN01983-15

00 Index and foreword SEN01984-15

Index SEN01985-15 q

Foreword and general information SEN01986-02

01 Specification SEN01987-01

Specification and technical data SEN01988-01

10 Structure, function and maintenance standard SEN01989-08

Engine and cooling system SEN01990-00 Power train SEN01991-00

Undercarriage and frame SEN01992-00 Hydraulic system, Part 1 SEN01993-00 Hydraulic system, Part 2 SEN01994-01 Hydraulic system, Part 3 SEN01995-01 Work equipment SEN01996-01 Cab and its attachments SEN01997-00 Electrical system SEN01998-05

20 Standard value table

30

SEN01999-03

Standard service value table SEN02624-03

Testing and adjusting

SEN02000-08

Testing and adjusting, Part 1 SEN02625-06

Testing and adjusting, Part 2 SEN02626-04 q

Testing and adjusting, Part 3 SEN02663-02

40 Troubleshooting

SEN02001-09

Failure code table and fuse locations SEN02627-04

General Information on troubleshooting SEN02628-04

Troubleshooting by failure code (Display of code), Part 1 SEN02629-03

Troubleshooting by failure code (Display of code), Part 2 SEN02630-05

Troubleshooting by failure code (Display of code), Part 3 SEN02631-02

Troubleshooting of electrical system (E-mode) SEN02632-02

Troubleshooting of hydraulic and mechanical system (H-mode) SEN02633-03

Troubleshooting of engine (S-mode) SEN02634-02

50 Disassembly and assembly SEN02002-09

General information on disassembly and assembly SEN02635-02

Engine and cooling system SEN02636-03 Power train SEN02637-02

Undercarriage and frame SEN02638-03

Hydraulic system SEN02639-02 Work equipment SEN02640-00 Cab and its attachments SEN02641-02 Electrical system SEN02642-02

90 Diagrams and drawings SEN02003-04

Hydraulic diagrams and drawings SEN02004-01 Electrical diagrams and drawings SEN02005-04

Hydraulic system, Part 3 SEN01995-01

Valve control................................................................................................................................2

PPC valve...................................................................................................................................4

Solenoid valve.............................................................................................................................26

PPC accumulator........................................................................................................................28

Return oil filter.............................................................................................................................29

Center swivel joint.......................................................................................................................30

Travel motor................................................................................................................................31

Swing motor................................................................................................................................43

Hydraulic cylinder........................................................................................................................52

Work equipment SEN01996-01

Work equipment..........................................................................................................................2

Dimensions of components.........................................................................................................4

Cab and its attachments SEN01997-00

Air conditioner piping...................................................................................................................2 Electrical system SEN01998-05

Engine control.............................................................................................................................2

Electronic control system............................................................................................................11

Monitor system............................................................................................................................36 Sensor.........................................................................................................................................63

KOMTRAX system......................................................................................................................66

20 Standard value table

Standard service value table SEN02624-03

Standard value table for engine related parts..............................................................................2

Standard value table for chassis related parts ............................................................................3

30 Testing and adjusting

Testing and adjusting, Part 1 SEN02625-06

Tools for testing, adjusting and troubleshooting..........................................................................3

Sketches of special tools.............................................................................................................7

Testing engine speed..................................................................................................................8

Testing air boost pressure...........................................................................................................9

Testing exhaust gas color............................................................................................................10

Adjusting valve clearance...........................................................................................................12

Testing compression pressure....................................................................................................14

Testing blow-by pressure............................................................................................................18

Testing engine oil pressure.........................................................................................................19

Testing fuel pressure...................................................................................................................20

Handling during cylinder cut-out operation ..................................................................................25

Handling during no injection cranking operation.........................................................................25

Testing fuel return rate and leakage............................................................................................26

Bleeding air from fuel circuit........................................................................................................28

Checking fuel circuit for leakage.................................................................................................29

Testing and adjusting air compressor belt tension......................................................................30

Replacing fan belt.......................................................................................................................31

Replacing alternator belt.............................................................................................................32

Testing clearance in swing circle bearings..................................................................................33

Testing and adjusting track shoe tension....................................................................................34

Testing and adjusting oil pressure in work equipment, swing and travel circuit..........................35

Testing and adjusting control circuit oil pressure.........................................................................39

Testing and adjusting pump PC control circuit oil pressure.........................................................40

Testing and adjusting pump LS control circuit oil pressure.........................................................43

Testing solenoid valve output pressure.......................................................................................48

Testing PPC valve output pressure.............................................................................................52

Adjusting play of work equipment and swing PPC valves...........................................................53

Inspecting locations of hydraulic drift of work equipment............................................................54

Releasing remaining pressure in hydraulic circuit.......................................................................56

Testing oil leakage amount..........................................................................................................56

Bleeding air from various parts....................................................................................................59 Diode inspection procedures... ...61

Installation and adjustment of mirrors......................................................................................... 62

Testing and adjusting, Part 2SEN02626-04 Special functions of machine monitor..........................................................................................2

Testing and adjusting, Part 3SEN02663-02 Handling voltage circuit of engine controller................................................................................2

Preparation work for troubleshooting of electrical system...........................................................3 Procedure for testing diodes.......................................................................................................7

Pm clinic service..........................................................................................................................8

40 Troubleshooting

Failure code table and fuse locations SEN02627-04 Failure codes table......................................................................................................................2 Fuse locations.............................................................................................................................5

General Information on troubleshooting SEN02628-04 Points to remember when troubleshooting..................................................................................2 Sequence of events in troubleshooting.......................................................................................3 Checks before troubleshooting....................................................................................................4 Classification and troubleshooting steps.....................................................................................5 Information in troubleshooting table............................................................................................6 Possible problems and troubleshooting No.................................................................................8

Connection table for connector pin numbers...............................................................................11 T- branch box and T- branch adapter table.................................................................................47

Troubleshooting by failure code (Display of code), Part 1

SEN02629-03

Failure code [989L00] Engine Controller Lock Caution 1............................................................3

Failure code [989M00] Engine Controller Lock Caution 2...........................................................3

Failure code [989N00] Engine Controller Lock Caution 3...........................................................4

Failure code [AA10NX] Air cleaner Clogging..............................................................................6

Failure code [AB00KE] Charge Voltage Low...............................................................................8

Failure code [B@BAZG] Eng Oil Press. Low..............................................................................10

Failure code [B@BAZK] Eng Oil Level Low................................................................................12

Failure code [B@BCNS] Eng. Water Overheat...........................................................................14

Failure code [B@BCZK] Eng Water Level Low...........................................................................16

Failure code [B@HANS] Hydr Oil Overheat................................................................................18

Failure code [CA111] EMC Critical Internal Failure.....................................................................19

Failure code [CA115] Eng Ne and Bkup Speed Sens Error........................................................19

Failure code [CA122] Chg Air Press Sensor High Error..............................................................20

Failure code [CA123] Chg Air Press Sensor Low Error..............................................................22

Failure code [CA131] Throttle Sensor High Error........................................................................24

Failure code [CA132] Throttle Sensor Low Error........................................................................26

Failure code [CA144] Coolant Temp Sens High Error.................................................................28

Failure code [CA145] Coolant Temp Sens Low Error..................................................................30

Failure code [CA153] Chg Air Temp Sensor High Error..............................................................32

Failure code [CA154] Chg Air Temp Sensor Low Error...............................................................34

Failure code [CA155] Chg Air Temp High Speed Derate............................................................36

Failure code [CA187] Sens Supply 2 Volt Low Error...................................................................38

Failure code [CA221] Ambient Press Sens High Error................................................................40

Failure code [CA222] Ambient Press Sens Low Error................................................................42

Failure code [CA227] Sens Supply 2 Volt High Error..................................................................44

Failure code [CA234] Eng Overspeed.........................................................................................45

Failure code [CA238] Ne Speed Sens Supply Volt Error.............................................................46

Failure code [CA271] IMV/PCV1 Short Error..............................................................................47

Failure code [CA272] IMV/PCV1 Open Error..............................................................................48

Failure code [CA281] Pump Press Balance Error.......................................................................50

PC300, 350-8

Failure code [CA322] Inj #1 (L/B#1) Open/Short Error...............................................................51

Failure code [CA323] Inj #5 (L/B#5) Open/Short Error...............................................................53

Failure code [CA324] Inj #3 (L/B#3) Open/Short Error...............................................................55

Failure code [CA325] Inj #6 (L/B#6) Open/Short Error...............................................................57

Failure code [CA331] Inj #2 (L/B#2) Open/Short Error...............................................................59

Failure code [CA332] Inj #4 (L/B#4) Open/Short Error...............................................................61

Troubleshooting by failure code (Display of code), Part 2SEN02630-05

Failure code [CA342] Calibration Code Incompatibility...............................................................3

Failure code [CA351] Injectors Drive Circuit Error......................................................................4

Failure code [CA352] Sens Supply 1 Volt Low Error...................................................................6

Failure code [CA386] Sens Supply 1 Volt High Error..................................................................8

Failure code [CA428] Water in Fuel Sensor High Error..............................................................10

Failure code [CA429] Water in Fuel Sensor Low Error...............................................................12

Failure code [CA435] Eng Oil Press Sw Error............................................................................14

Failure code [CA441] Battery Voltage Low Error ........................................................................16

Failure code [CA442] Battery Voltage High Error ........................................................................18

Failure code [CA449] Rail Press Very High Error.......................................................................20

Failure code [CA451] Rail Press Sensor High Error...................................................................24

Failure code [CA452] Rail Press Sensor Low Error....................................................................26

Failure code [CA488] Chg Air Temp High Torque Derate...........................................................28

Failure code [CA553] Rail Press High Error................................................................................28

Failure code [CA559] Rail Press Low Error................................................................................30

Failure code [CA689] Eng Ne Speed Sensor Error.....................................................................32

Failure code [CA731] Eng Bkup Speed Sens Phase Error.........................................................34

Failure code [CA757] All Persistent Data Lost Error...................................................................36

Failure code [CA778] Eng Bkup Speed Sensor Error.................................................................38

Failure code [CA1633] KOMNET Datalink Timeout Error...........................................................40

Failure code [CA2185] Throt Sens Sup Volt High Error..............................................................42

Failure code [CA2186] Throt Sens Sup Volt Low Error...............................................................43

Failure code [CA2249] Rail Press Very Low Error......................................................................44

Failure code [CA2265] Fuel Feed Pump Open Error..................................................................46

Failure code [CA2266] Fuel Feed Pump Short Error..................................................................48

Failure code [CA2311] IMV Solenoid Error.................................................................................50

Failure code [CA2555] Grid Htr Relay Volt Low Error.................................................................52

Failure code [CA2556] Grid Htr Relay Volt High Error................................................................54

Failure code [D110KB] Battery Relay Drive S/C.........................................................................56

Failure code [D19JKZ] Personal Code Relay Abnormality.........................................................58

Failure code [D862KA] GPS Antenna Discon.............................................................................60

Failure code [DA22KK] Pump Solenoid Power Low Error..........................................................61

Failure code [DA25KP] 5V sensor 1 power abnormality.............................................................63

Failure code [DA29KQ] Model Selection Abnormality.................................................................66

Failure code [DA2RMC] Pump Comm. Abnormality...................................................................68

Failure code [DAF8KB] Short circuit in camera power supply....................................................70

Failure code [DAFGMC] GPS Module Error...............................................................................72

Troubleshooting by failure code (Display of code), Part 3SEN02631-02

Failure code [DAFRMC] CAN discon (Monitor detected)............................................................4

Failure code [DGH2KB] Hydr Oil Sensor Short...........................................................................6

Failure code [DHPAMA] F Pump Press Sensor Abnormality......................................................8

Failure code [DHPBMA] R Pump Press Sensor Abnormality.....................................................10

Failure code [DHS3MA] Arm Curl PPC Sensor Abnormality......................................................12

Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality........................................14

Failure code [DHX1MA] Overload Sensor Abnormality (Analog)................................................16

Failure code [DW43KA] Travel Speed Sol. Open Circuit............................................................18

Failure code [DW43KB] Travel Speed Sol. Short Circuit.............................................................20

Failure code [DW45KA] Swing Brake Sol. Open Circuit.............................................................22

Failure code [DW45KB] Swing Brake Sol. Short Circuit .............................................................26

Failure code [DW91KA] Travel Junction Sol. Open Circuit.........................................................28

Failure code [DW91KB] Travel Junction Sol. Short Circuit.........................................................30

Failure code [DWA2KA] Attachment Sol Open Circuit................................................................32

Failure code [DWA2KB] Attachment Sol Short Circuit................................................................33

Failure code [DWJ0KA] Merge-divider Sol. Open Circuit............................................................34

Failure code [DWJ0KB] Merge-divider Sol. Short Circuit............................................................36

Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit...........................................................38

Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit...........................................................40

Failure code [DXA0KA] PC-EPC Sol. Open Circuit.....................................................................42

Failure code [DXA0KB] PC-EPC Sol. Short Circuit.....................................................................44

Failure code [DXE0KA] LS-EPC Sol. Open Circuit.....................................................................46

Failure code [DXE0KB] LS-EPC Sol. Short Circuit.....................................................................48

Failure code [DXE4KA] Service Current EPC Open Circuit........................................................50

Failure code [DXE4KB] Service Current EPC Short Circuit........................................................51

Failure code [DY20KA] Wiper Working Abnormality...................................................................52

Failure code [DY20MA] Wiper Parking Abnormality....................................................................54

Failure code [DY2CKA] Washer Drive Open Circuit....................................................................56

Failure code [DY2CKB] Washer Drive Short Circuit....................................................................58

Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit............................................................60

Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit.......... .........62

Troubleshooting of electrical system (E-mode)SEN02632-02

Before carrying out troubleshooting of electrical system.............................................................4 Information contained in troubleshooting table............................................................................6

E-1 Engine does not start............................................................................................................7

E-2 Auto-decelerator does not operate.......................................................................................10

E-3 Automatic warming-up system does not operate..................................................................12 E-4 Preheater does not operate........................ .14 E-5 All work equipment, swing, and travel mechanism do not move..........................................16 E-6 Power maximizing function does not operate.......................................................................18 E-7 Machine monitor does not display at all................................................................................20 E-8 Machine monitor does not display some items.....................................................................22 E-9 Contents of display by machine monitor are different from applicable machine...................22 E-10 Fuel level monitor was lighted in red while engine running................................................23 E-11 Engine coolant temperature gauge does not indicate normally..........................................24 E-12 Hydraulic oil temperature gauge does not indicate normally..............................................26 E-13 Fuel level gauge does not indicate normally.......................................................................27 E-14 Swing lock monitor does not indicate normally...................................................................28 E-15 When monitor switch is operated, monitor displays nothing...............................................30 E-16 Windshield wiper and window washer do not operate........................................................32 E-17 Machine push-up function does not operate normally........................................................36 E-18 Monitoring function fails to display “boom raise” normally..................................................38 E-19 Monitoring function fails to display “boom lower” normally.................................................40 E-20 Monitoring function fails to display “arm IN” normally.........................................................42 E-21 Monitoring function fails to display “arm OUT” normally.....................................................44 E-22 Monitoring function fails to display “bucket CURL” normally..............................................46 E-23 Monitoring function fails to display “bucket DUMP” normally..............................................48 E-24 Monitoring function fails to display “swing” normally...........................................................50 E-25 Monitoring function fails to display “travel” normally...........................................................52 E-26 Monitoring function fails to display “travel differential pressure” normally..........................54 E-27 Monitoring function fails to display “service” normally........................................................56 E-28 KOMTRAX system does not operate normally...................................................................58 E-29 Air conditioner does not operate.........................................................................................60 E-30 Travel alarm does not sound or does not stop sounding....................................................62 E-31 Horn does not sound..........................................................................................................64

Troubleshooting of hydraulic and mechanical system (H-mode) SEN02633-03 System chart for hydraulic and mechanical system....................................................................4 Information contained in troubleshooting table............................................................................6

H-1 All work equipment lack power, or travel and swing speeds are slow..................................8 H-2 Engine speed sharply drops or engine stalls ........................................................................10 H-3 No work equipment, swing or travel move............................................................................11

H-4 Abnormal noise is heard from around hydraulic pump.........................................................11

H-5 Auto-decelerator does not work...........................................................................................12

H-6 Fine control mode does not function or responds slow........................................................12

H-7 Boom moves slowly or lacks power.....................................................................................13

H-8 Arm moves slowly or lacks power........................................................................................14

H-9 Bucket moves slowly or lacks power....................................................................................15

H-10 Work equipment does not move in its single operation......................................................15

H-11 Work equipment has a bit too fast hydraulic drift................................................................16

H-12 Work equipment has big time lag.......................................................................................18

H-13 Other work equipment moves when relieving single circuit................................................18

H-14 Power max. switch does not operate......... ........................................................................19

H-15 In compound operation, work equipment with larger load moves slowly ...........................19

H-16 In swing + boom RAISE operation, boom moves slowly....................................................20

H-17 In swing + travel operation, travel speed drops sharply.....................................................20

H-18 Machine swerves in travel..................................................................................................21

H-19 Machine travels slowly.......................................................................................................22

H-20 Machine cannot be easily steered or lacks power..............................................................23

H-21 Travel speed does not shift, or it is too slow or fast............................................................24

H-22 Track shoe does not turn (on one side only)......................................................................25

H-23 Machine does not swing.....................................................................................................26

H-24 Swing acceleration is poor, or swing speed is slow............................................................28

H-25 Excessive overrun when stopping swing............................................................................30

H-26 There is big shock when stopping swing............................................................................31

H-27 Large sound is made when upper structure stops swinging..............................................31

H-28 Swing hydraulic drift is too big............................................................................................32

Troubleshooting of engine (S-mode) SEN02634-02

Method of using troubleshooting chart........................................................................................3

S-1 Starting performance is poor................................................................................................6

S-2 Engine does not start............................................................................................................7

S-3 Engine does not pick up smoothly........................................................................................10

S-4 Engine stops during operations............................................................................................11

S-5 Engine does not rotate smoothly..........................................................................................12

S-6 Engine lacks output (or lacks power)............ ........................................................................13

S-7 Exhaust smoke is black (incomplete combusti on)................................................................14

S-8 Oil consumption is excessive (or exhaust smoke is blue)....................................................15

S-9 Oil becomes contaminated quickly.......................................................................................16

S-10 Fuel consumption is excessive...........................................................................................17

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................18

S-12 Oil pressure drops..............................................................................................................19

S-13 Oil level rises (Entry of coolant or fuel) ...............................................................................20

S-14 Coolant temperature becomes too high (overheating).......................................................21

S-15 Abnormal noise is made.....................................................................................................22 S-16 Vibration is excessive.........................................................................................................23

Removal and installation of aftercooler assembly.......................................................................30

Removal and installation of engine and hydraulic pump assembly.............................................31

Power train SEN02637-02

Removal and installation of final drive assembly .........................................................................2

Disassembly and assembly of final drive assembly....................................................................3

Removal and installation of swing motor and swing machinery assembly..................................11

Disassembly and assembly of swing motor and swing machinery assembly.............................12

Removal and installation of swing circle assembly.....................................................................19

Undercarriage and frameSEN02638-03

Disassembly and assembly of carrier roller.................................................................................2

Disassembly and assembly of track roller assembly...................................................................3

Disassembly and assembly of idler assembly...... .......................................................................4

Disassembly and assembly of recoil spring................................................................................7

Removal and installation of sprocket........................................................................................... 9

Expansion and installation of track shoe assembly.....................................................................10

Removal and installation of revolving frame assembly...............................................................12

Removal and installation of counterweight assembly..................................................................14

Hydraulic systemSEN02639-02

Removal and installation of center swivel joint assembly............................................................2

Disassembly and assembly of center swivel joint assembly.......................................................4

Removal and installation of hydraulic tank assembly..................................................................5

Removal and installation of control valve assembly....................................................................7

Disassembly and assembly of control valve assembly...............................................................10

Removal and installation of hydraulic pump assembly................................................................11

Removal and installation of oil seal in hydraulic pump input shaft..............................................13

Disassembly and assembly of work equipment PPC valve assembly........................................14

Disassembly and assembly of travel PPC valve assembly.........................................................16

Disassembly and assembly of hydraulic cylinder assembly........................................................19

Work equipmentSEN02640-00

Removal and installation of work equipment assembly...............................................................2

Cab and its attachmentsSEN02641-02

Removal and installation of operator's cab assembly.................................................................2

Removal and installation of operator cab glass (stuck glass).....................................................5

Removal and installation of front window assembly....................................................................15

Removal and installation of floor frame assembly.......................................................................22

Electrical systemSEN02642-02

Removal and installation of air conditioner unit assembly...........................................................2

Removal and installation of KOMTRAX communication modem assembly................................5

Removal and installation of monitor assembly............................................................................6

Removal and installation of pump controller assembly...............................................................8

Removal and installation of engine controller..............................................................................10 90

Hydraulic

PC300, 350-8

Safety

notice 1 (Rev. 2008/08)

Important safety notice

Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.

To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

1.General precautions

k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

1)Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.

2)Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

3)When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

q Always wear safety glasses when hitting parts with a hammer.

q Always wear safety glasses when grinding parts with a grinder, etc.

4)When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment.

5)Only qualified workers must carry out work and operation which require license or qualification.

6)Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.

7)If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.

8)Before starting work, warm up your body thoroughly to start work under good condition.

9)Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.

Safety points

1Good arrangement 2Correct work clothes 3Following work standard 4Making and checking signs 5 Prohibition of operation and handling by unlicensed workers 6Safety check before starting work 7 Wearing protective goggles (for cleaning or grinding work) 8 Wearing shielding goggles and protectors (for welding work) 9Good physical condition and preparation 10 Precautions against work which you are not used to or you are used to too much

2.Preparations for work

1)Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving.

2)Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

3)When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work.

4)Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

3.Precautions during work

1)Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out.

2)The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits.

3)Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts.

4)Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first.

5)When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

6)When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover.

7)When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires.

8)When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires.

9)As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular.

10)Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated.

11)When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check that connecting parts are correctly installed.

12)When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.

13)When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

14)When measuring hydraulic pressure, check that the measuring tools are correctly assembled.

15)Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

16)If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

4.Precautions for sling work and making signs

1)Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely.

q Do not stand under the load.

q Do not step on the load.

2)Check the slings before starting sling work.

3)Keep putting on gloves during sling work. (Put on leather gloves, if available.)

4)Measure the weight of the load by the eye and check its center of gravity.

5)Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.

6)Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.

k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

7)Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.

8)When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.

9)Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc.

10)Apply wire ropes to the middle portion of the hook.

q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11)Do not use twisted or kinked wire ropes.

12)When lifting up a load, observe the following.

q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.

q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

q If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.

q Do not lift up the load slantingly.

13)When lifting down a load, observe the following.

q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.

q Check that the load is stable, and then remove the sling.

q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

5.Precautions for using mobile crane

a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.

6.Precautions for using overhead hoist crane

k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4

1)Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety.

2)Observe the signs for sling work.

3)Operate the hoist at a safe place.

4)Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail.

5)Do not sling a load slantingly. Do not move the crane while the slung load is swinging.

6)Do not raise or lower a load while the crane is moving longitudinally or laterally.

7)Do not drag a sling.

8)When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up.

9)Consider the travel route in advance and lift up a load to a safe height.

10)Place the control switch on a position where it will not be an obstacle to work and passage.

11)After operating the hoist, do not swing the control switch.

12)Remember the position of the main switch so that you can turn off the power immediately in an emergency.

13)If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state.

14)If you find an obstacle around the hoist, stop the operation.

15)After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

7.Selecting wire ropes

1)Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.

Wire ropes

(Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A)

Nominal diameter of rope Allowable load mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

a The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

Komatsu Hydraulic Excavator Pc300 8 60001 Shop Manual

Full download: http://manualplace.com/download/komatsu-hydraulic-excavator-pc300-8-60001-shop-manual/

8.Precautions

for disconnecting and connecting hoses and tubes in air conditioner circuit

1)Disconnection

k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it.

a Ask professional traders for collecting and filling operation of refrigerant (R134a).

a Never release the refrigerant (R134a) to the atmosphere.

k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person.

2)Connection

1]When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them.

2]When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints.

3]Check that each O-ring is not damaged or deteriorated.

4]When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VALEO THERMAL SYSTEMS: ZXL100PG (equivalent to PAG46)) to its O-rings.

a Example of O-ring (Fitted to every joint of hoses and tubes)

a For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".